Panel mounting bracket with under-mounting clamp and related methods

ABSTRACT

A system for mounting a solar panel(s) on a building, where the solar panel has an outer frame defining a lip. The system may include a plurality of panel mounting brackets each including a base to be positioned on the building, and a vertical extension having a proximal end coupled to the base and a distal end vertically spaced apart from the base, with the distal end defining a fastener channel therein. The system may also include a plurality of mounting clamps each including a bottom flange, and a top flange spaced apart from the bottom flange and partially overhanging the bottom flange and defining a slot therebetween to receive the lip. An end extension may couple respective ends of the bottom flange and top flange together, and a fastener channel connector may be coupled to the bottom flange and configured to be slidably received within the fastener channel.

This application is a divisional of U.S. patent application Ser. No.14/528,399 filed Oct. 30, 2014, which claims the benefit of provisionalapplication Ser. No. 61/897,473 filed Oct. 30, 2013, which are allhereby incorporated herein in their entireties by reference.

TECHNICAL FIELD

The present disclosure generally relates to mounting fixtures, and, moreparticularly, to mounting fixtures or brackets for rooftop panelinstallations, such as for solar panels, for example.

BACKGROUND

Solar panels, such as photovoltaic (PV) and solar water heating panels,are frequently used to take advantage of electrical power generation andheating properties of sunlight. To provide space savings and potentiallyenhanced efficiency, solar panels are in many cases installed onrooftops of buildings (e.g., office buildings, houses, etc.). However,because of winds and storms, the mounting fixtures used for installingsolar panels on buildings need to be sufficiently strong and durable toreduce the chances of damage or injury from a panel coming loose duringa storm, etc.

Various mounting fixtures have been developed for solar panelinstallation. For example, U.S. Pat. No. 7,963,074 discloses a devicefor fixing a photovoltaic module on a sloping roof having a roofstructure and a roof covering with individual roof covering elements.The device includes a roof-side connecting piece disposable beneath theroof covering and a module-side connecting piece disposable on an edgeof the photovoltaic module. A flexible retaining element interconnectsthe roof-side connecting piece and the module-side connecting piece. Theflexible retaining element is loadable by pulling and adapted to beguided through the roof covering without altering a position or shape ofthe individual roof covering elements.

Despite the existence of such mounting fixtures, further enhancementsmay be desirable in some applications.

SUMMARY

A system for mounting at least one solar panel on a building isprovided, where the solar panel has an outer frame defining a lip. Thesystem may include a plurality of panel mounting brackets each includinga base to be positioned on the building, and a vertical extension havinga proximal end coupled to the base and a distal end vertically spacedapart from the base, the distal end defining a fastener channel therein.The system may also include a plurality of mounting clamps eachincluding a bottom flange, a top flange spaced apart from the bottomflange and partially overhanging the bottom flange and defining a slottherebetween to receive the lip of the at least one solar panel, an endextension coupling respective ends of the bottom flange and top flangetogether, and a fastener channel connector coupled to the bottom flangeand configured to be slidably received within the fastener channel.

More particularly, the fastener channel connector may comprise aT-shaped connector coupled to the bottom flange on a side thereofopposite the top flange and configured to be slidably received withinthe fastener channel. In accordance with another example embodiment, thefastener channel connector may include a horizontal member having anupper surface coupled to the bottom flange and a lower surface to bepositioned on the distal end of the vertical extension, a pair of spacedapart vertical side members on opposite sides of the horizontal memberand configured to extend along the distal end of the vertical extensionwhen the lower surface of the horizontal member is positioned on thedistal end of the vertical extension, a bolt coupled to the lowersurface of the horizontal member and configured to extend downward intothe fastener channel when the lower surface of the horizontal member ispositioned on the distal end of the vertical extension, and a nut to bescrewed onto the bolt and configured to be slidably received within thefastener channel.

In an example embodiment, the at least one solar panel may comprise aplurality of solar panels, and the fastener channel of each verticalextension may be configured to slidably receive at fastener channelconnectors of least two mounting clamps each coupled to the outer frameof different respective solar panels. Each mounting clamp may furtherinclude at least one set screw carried by the bottom flange to securethe lip of the at least one solar panel within the slot.

The vertical extension may be laterally centered on the base, forexample. Also by way of example, each panel mounting bracket maycomprise aluminum. Furthermore, the base may define a plurality ofmounting holes on opposing sides of the vertical extension. In oneexample embodiment, the vertical extension member may be hollow and mayhave a plurality of cross-support members therein.

A related solar panel mounting assembly including a panel mountingbracket and a mounting clamp as described briefly above are alsoprovided. Moreover, a method for mounting at least one solar panel on abuilding using a plurality of the solar panel mounting assemblies isalso provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an end view of a panel mounting bracket in accordance with anexemplary embodiment of the invention including an under-mounting clamp.

FIG. 2 is a top view of the mounting bracket of FIG. 1 with mountingholes for securing the bracket to a structure.

FIG. 3 is a side view of the mounting bracket with a single mountingclamp for attaching to the exterior sides of panels located at theperimeter of a panel array.

FIG. 4 is a side view of a mounting bracket attached to the frame of theunderside of a panel at the perimeter of a panel array.

FIG. 5 is a side view of a mounting bracket with two mounting clamps forattaching to respective frames of two adjacent modules.

FIG. 6 is an end view of a mounting bracket with two mounting clampsrespectively connected to two adjacent modules.

FIG. 7 is a three-dimensional perspective view of a pair of mountingbrackets as shown in FIG. 4 each having a respective mounting clampcoupled to a same panel.

FIG. 8 is a top view of two panels as they would appear installed on arooftop using a plurality of the bracket assemblies illustrated in FIGS.4 and 6.

FIGS. 9-11 are respective side, end, and perspective illustrations ofanother example mounting bracket assembly which includes another examplefastener channel connector configuration.

DETAILED DESCRIPTION

The present description is made with reference to the accompanyingdrawings, in which exemplary embodiments are shown. However, manydifferent embodiments may be used, and thus the description should notbe construed as limited to the embodiments set forth herein. Rather,these embodiments are provided so that this disclosure will be thoroughand complete. Like numbers refer to like elements throughout, and primenotation is used to indicate similar elements in different embodiments.

Referring initially to FIGS. 1-8, an assembly 30 for mounting one ormore solar panels 31 on a building (e.g., on a roof) is first described.The assembly 30 illustratively includes a mounting bracket 32 (which isalso referred to as a “foot” herein) for installing solar panels ormodules 31. By way of background, solar modules or panels are typicallymounted to racking using clamps that grip the module and hold it tightto rails which are mounted to rooftops by “L” shaped feet. The foot 32illustrated in FIG. 1 advantageously avoids the need for such rails andclamps by mounting panels to roofs through the use of multiple feet(e.g., four feet, although other numbers of feet may be used), which areattached to the underside of each panel. More particularly, each panel31 may include an outer frame 33 defining a lip 34 on the undersidethereof, and in the example embodiment illustrated in FIGS. 7 and 8 theouter frame carries a photovoltaic cell array 35 therein (although theassembly 30 may also be used for mounting solar hot water heating panelsas well, for example).

In the illustrated example, the foot 32 has a generallyrectangular-shaped central vertical extension portion 36 with one ormore hollow central area(s) or channel(s) 37 therethrough. A proximalend 38 of the vertical extension 36 is coupled to a flange or base 39 ofthe foot 32, and a distal end 40 of the vertical extension is verticallyspaced apart from the proximal end, as seen in FIG. 1. An upper fastenerchannel slot or groove 41 is defined in the distal end 40 (see FIG. 2),though grooves may instead or in addition be provided on either or bothsides of the vertical extension 36 in some embodiments, if desired. Thefoot 32 has a height h and a width w, which in an example embodiment mayboth be three inches, but other dimensions may also be used in differentembodiments.

The base 39 illustratively includes two side extensions 42, 43 thatextend outwardly away from the vertical extension 36 so that thevertical extension is centered on the base (although it need not becentered in all embodiments). Thus, when the bottom surface of the base39 sits flat on a rooftop or roof deck 44 upon installation, thevertical extension 36 points upward or normal to the surface of the roof(although the vertical extension may form different angles with respectto the base besides 90° in different embodiments). Serrations or othersurface features may optionally be included on portions of the uppersurface of the distal end 40 and/or the bottom surface of the base 39,if desired. The serrations may advantageously provide for improvedelectrical grounding with the frame of the panel, as well as increasedgrip or friction, for example, as will be appreciated by those skilledin the art.

In the illustrated example, the feet 32 are attached to the undersidelip 34 of each panel frame 33, as shown in FIGS. 4 and 7. While still onthe ground, the installation technician may advantageously attach thefeet 32 to the bottom of each panel on their longer sides (e.g., top andbottom sides) with the front edge of the foot facing out from the panelusing an under-mounting clamp 50. However, the feet 32 may be attachedto the other sides of the panels 31 as well in some embodiments, and thepanels may also be attached to the feet after the feet have beeninstalled on the rooftop 44, if desired.

The mounting clamp 50 illustratively includes a bottom flange 51, a topflange 52 spaced apart from the bottom flange and partially overhangingthe bottom flange (see FIG. 3) to define a slot therebetween, and an endextension 53 coupling respective ends of the bottom flange and topflange together. The slot is configured to engage or receive the lip 34of the solar panel 31, as seen in FIG. 7. The mounting clamp 50 furtherillustratively includes a fastener channel connector 54 coupled to thebottom flange 51 and configured to be slidably received within thefastener channel 41.

In the present example, the fastener channel connector 54 illustrativelyincludes a T-shaped connector or slide bar coupled to the bottom flange51 on a side thereof opposite the top flange 52 (i.e., on its bottomside). The T-shaped connector 57 is configured to be slidably receivedwithin the fastener channel 41, as seen in FIGS. 1 and 2. The fastenerchannel connector 54 may first be attached to the solar panel 31, andthen the feet 32 connected to respective mounting clamps 50. Anotherapproach is that the mounting clamps 50 may be coupled to respectivefeet 32, and the entire assembly 30 (i.e., mounting clamp plus foot) maythen be connected to the solar panel 31. The mounting clamp 50 furtherillustratively includes a retaining set screw(s) 55 which may betightened to secure the lip 34 within the slot between the bottom andtop flanges 51, 52, and a slide bar retaining bolt 58 and acorresponding nut 59.

A first row of panels 31 may then be attached on the roof 44 with deckscrews 60 through mounting holes 61 in the side extensions 42, 43 on theoutward or perimeter side of the array, typically in a straight line. Insome instances, a sealant may be used under each foot 32, if desired.Various types of sealant may be used, such as caulking, tar, Butyl tape,etc. An adjacent row of solar panels 31 may then be attached withadditional feet 32 adjacent to the first row of solar panels so as toshare the second set of feet (see FIGS. 5 and 6) between them. That is,the fastener channel 41 of each vertical extension portion may be ofsufficient dimensions or length to slidably receive two (or more)fastener channel connectors 54 therein. While the feet 32 are sharedbetween adjacent panels, the mounting clamps 50 retain each solar panel31 independently. This allows each solar panel 31 to be installed andsecured individually, and in the event that a solar panel is to beremoved from an array, this can be done independently without looseningthe adjacent solar panel, which is generally not possible with typicalpanel or panel mounting arrangements.

The installation process may be repeated for each row of solar panels 31to be installed, until the last row of solar panels is reached. On theouter perimeter of the last solar panel 31, one mounting clamp 50 may beused per foot 32 to attach to the outer edge of each of the perimetersolar panels (see, e.g., FIGS. 4 and 7).

A significant advantage of the assembly 30 is that it may advantageouslybe connected or coupled to a respective solar panel 31 on the ground,rather than having to be coupled to the solar panel on the roof 44 wherethis is more difficult (and potentially more dangerous), and where it ismuch harder to recover dropped tools, screws, nuts, washers, or otherparts. Moreover, this may also help expedite the installation process.

The hollow channels or passageways 37 in the vertical extension 36 mayserve as wire management channels, which may be used for keepingelectrical transmission wires (e.g., for PV panels) or temperaturesensor wires (e.g., for a water heater panels) secured in place.However, the cross-support members 56 which define the channels 37 neednot be included in all embodiments, although even when the channels arenot used for routing wires the cross-support members may provide addedrigidity and/or stability to the feet 32. It should also be noted thatthe vertical extension 36 of the foot 32 need not be hollow in allembodiments, and that different shapes beside a rectangular shape mayalso be used for the base 39 and/or the vertical extension in someembodiments. Example materials for the foot 32 and the mounting clamp 50may include aluminum, which may be extruded into the desired shape,although other suitable materials may also be used in differentembodiments. The various screws and fasteners described herein may bestainless steel, brass, galvanized steel, etc.

Here again, a sealant may optionally be used under each foot 32 so thatthe screws 60 are screwed through the foot 32 and sealant into the roofor decking 44 at desired locations. By way of example, two or more feet32 may be secured to the roof 44 to receive one side of the panel, i.e.,two (or more) feet are used on each of the top and bottom sides or edgesof the solar panel 31, as shown in FIG. 7, although in some embodimentsa single foot may be used.

It should be noted that the above-described mounting assembly 30 may beused with a variety of roof types, including flat and sloped roofs, andover different types of roof coverings (e.g., shingles, tiles, panels,etc.). Moreover, the mounting feet may be used for installations otherthan on rooftops, such as where mounting to the side of a building orother structure is required.

In accordance with another example embodiment now described withreference to FIGS. 9-11, the fastener channel connector 54′ may in thisconfiguration include a horizontal base or platform member 70′ having anupper surface coupled to the mounting clamp 50′ and a lower surfacepositioned on the distal end 40′ of the vertical extension 35′, insteadof the slide bar configuration shown in FIG. 1. A pair of spaced apartvertical side members 71′ are coupled to opposite sides of thehorizontal member 70′ and extend along the distal end 40′ of thevertical extension 36′ when the lower surface of the horizontal memberis positioned on the distal end of the vertical extension 36′. Statedalternatively, this configuration generally has an inverted “U” shape(as seen from the end view of FIG. 10) defining a channel that fits onthe distal end 40′ of the vertical extension 36′. A bolt 72′ is coupledto the horizontal member 70′ and configured to extend downward into thefastener channel 41′ when the lower surface of the horizontal member ispositioned on the distal end 40′ of the vertical extension 36′, and anut 73′ may be screwed onto the bolt and configured to be slidablyreceived within the fastener channel.

In the present example, the fastener channel connector 54′ allows forthe mounting clamp 50′ of each independent solar panel to remainattached to that solar panel, but yet be removed from the correspondingmounting bracket 32′, allowing each solar panel to be detached from itsmounts by removing each retaining bolt 72′ and nut 73′. This facilitatesthe removal of solar panels independent from other panels within thearray without the disruption of adjacent panels, which again may not bepossible with typical mounting systems.

In another example embodiment, the above-described assembly 30 may beused for mounting solar panels without an outer frame (i.e., a framelesspanel or module). That is, the mounting clamps 50 could be coupleddirectly to the photovoltaic cell array 35, by directing the slotbetween the bottom and top flanges 51, 52 inward to receive the cellarray panel therein (as opposed to the slots facing outward to receivethe outer frame lip 34 as described above). To this end, a material suchas rubber, etc., may be positioned or adhered within the slot to helpprotect and/or securely hold the cell array 35. Moreover, the set screw55 may still be used to secure the cell array 35 within the slot, and insome configurations a small plate (e.g., stainless steel plate, etc.)may be coupled to or actuated by the set screw to be pressed intocontact to secure the cell array within the slot, as will be appreciatedby those skilled in the art. This may be beneficial to help keep theglass substrate upon which the cell array 35 is formed from cracking,for example.

Many modifications and other embodiments of the invention will come tothe mind of one skilled in the art having the benefit of the teachingspresented herein. For example, in addition to eyeglasses, theabove-described approach may be used with other wearable accessories,such as watches, bracelets, etc. Therefore, it is understood that theinvention is not to be limited to the specific exemplary embodimentsdisclosed herein.

That which is claimed is:
 1. A method for mounting a plurality of solarpanels on a building, each one of the plurality of solar panelscomprising an outer frame defining a lip, the method comprising:coupling a plurality of panel mounting bracket assemblies to theplurality of solar panels, each of the panel mounting bracket assembliescomprising a base to be positioned on the building, a vertical extensionhaving a proximal end coupled to the base and a distal end verticallyspaced apart from the base, the distal end defining a fastener channeltherein, and a plurality of mounting clamps each comprising a bottomflange having first and second ends, a top flange having first andsecond ends, the top flange spaced apart from the bottom flange anddefining a slot therebetween to receive the lip of a respective one ofthe plurality of solar panels, an end extension coupling the first endsof the bottom flange and the top flange together, at least one set screwextendable into the slot between the top and bottom flanges to contactthe lip of the respective solar panel and secure the lip within theslot, and a fastener channel connector coupled to the bottom flange andconfigured to be slidably received within the fastener channel of arespective vertical extension; and coupling the bases of the mountingbrackets to the building with the solar panels attached thereto, whereinat least two fastener channel connectors are connected to a fastenerchannel of a same vertical extension.
 2. The method of claim 1 whereinthe fastener channel connector comprises a T-shaped connector coupled tothe bottom flange on a side thereof opposite the top flange; and whereinthe coupling of the plurality of panel mounting bracket assemblies tothe plurality of solar panels further comprises sliding the T-shapedconnector of each mounting clamp into a fastener channel of a respectivepanel mounting bracket.
 3. The method of claim 2 wherein each one of theplurality of mounting clamps further comprises a retaining bolt and acorresponding nut coupling the T-shaped connector to the bottom flange.4. The method of claim 1 wherein the at least one set screw is carriedby the bottom flange; and wherein the coupling of the panel mountingbracket assemblies to the plurality of solar panels further comprisestightening the at least one set screw to secure the lip within the slot.5. The method of claim 1 wherein at least one set screw is carried bythe top flange; and wherein the coupling of the panel mounting bracketassemblies to the plurality of solar panels further comprises tighteningthe at least one set screw to secure the lip within the slot.
 6. Themethod of claim 1 wherein the vertical extension is laterally centeredon the base.
 7. The method of claim 1 wherein each one of the pluralityof panel mounting brackets comprises aluminum.
 8. The method of claim 1wherein the base defines a plurality of mounting holes on opposing sidesof the vertical extension.
 9. The method of claim 1 wherein the verticalextension is hollow and comprises at least one cross-support membertherein.
 10. The method of claim 1 wherein the fastener channelconnector comprises a horizontal member having an upper surface coupledto the bottom flange and a lower surface to be positioned on the distalend of the vertical extension, a pair of spaced apart vertical sidemembers on opposite sides of the horizontal member and configured toextend along the distal end of the vertical extension when the lowersurface of the horizontal member is positioned on the distal end of thevertical extension, a bolt coupled to the lower surface of thehorizontal member and configured to extend downward into the fastenerchannel when the lower surface of the horizontal member is positioned onthe distal end of the vertical extension, and a nut to be screwed ontothe bolt; and wherein the coupling of the plurality of panel mountingbracket assemblies to the plurality of solar panels further comprisessliding the nut of each mounting clamp into the fastener channel of arespective panel mounting bracket.
 11. A method for mounting at leastone solar panel on a building, the at least one solar panel comprisingan outer frame defining a lip, the method comprising: coupling aplurality of panel mounting bracket assemblies to the at least one solarpanel, each of the panel mounting bracket assemblies comprising a baseto be positioned on the building, a vertical extension having a proximalend coupled to the base and a distal end vertically spaced apart fromthe base, the distal end defining a fastener channel therein, and amounting clamp comprising a bottom flange having first and second ends,a top flange having first and second ends, the top flange spaced apartfrom the bottom flange and defining a slot therebetween to receive thelip of the at least one solar panel, an end extension coupling the firstends of the bottom flange and the top flange together, and a fastenerchannel connector coupled to the bottom flange and configured to beslidably received within the fastener channel of a respective verticalextension, the fastener channel connector comprising a horizontal memberhaving an upper surface coupled to the bottom flange and a lower surfaceto be positioned on the distal end of the vertical extension, a pair ofspaced apart vertical side members on opposite sides of the horizontalmember and configured to extend along the distal end of the verticalextension when the lower surface of the horizontal member is positionedon the distal end of the vertical extension, a bolt coupled to the lowersurface of the horizontal member and configured to extend downward intothe fastener channel when the lower surface of the horizontal member ispositioned on the distal end of the vertical extension, and a nut to bescrewed onto the bolt and configured to be slidably received within thefastener channel; and coupling the bases of the mounting bracketassemblies to the building with the at least one solar panel attachedthereto.
 12. The method of claim 11 wherein each of the plurality ofmounting clamps further comprises at least one set screw carried by thebottom flange; and wherein the coupling of the panel mounting bracketassemblies to the at least one solar panel further comprises tighteningthe at least one set screw to secure the lip within the slot.
 13. Themethod of claim 11 wherein each of the plurality of mounting clampsfurther comprises at least one set screw carried by the top flange; andwherein the coupling of the panel mounting bracket assemblies to the atleast one solar panel further comprises tightening the at least one setscrew to secure the lip within the slot.
 14. The method of claim 11wherein the vertical extension is laterally centered on the base. 15.The method of claim 11 wherein the vertical extension is hollow andcomprises at least one cross-support member therein.
 16. A method formounting at least one solar panel on a building, the at least one solarpanel comprising an outer frame defining a lip, the method comprising:coupling a plurality of solar panel mounting assemblies to the at leastone solar panel, each solar panel mounting assembly comprising a panelmounting bracket comprising a base to be positioned on a building, avertical extension having a proximal end coupled to the base and adistal end vertically spaced apart from the base, the distal enddefining a fastener channel therein, and a mounting clamp comprising abottom flange having and end, a top flange having an end and beingspaced apart from the bottom flange and partially overhanging the bottomflange and defining a slot therebetween and receiving the lip of the atleast one solar panel therein, an end extension coupling the ends of thebottom flange and top flange together, at least one set screw extendableinto the slot between the upper and lower flanges to contact the lip ofthe respective solar panel and secure the lip within the slot, and afastener channel connector coupled to the bottom flange and configuredto be slidably received within the fastener channel; and coupling thebases of the mounting brackets to the building with the at least onesolar panel attached thereto.
 17. The method of claim 16 wherein thefastener channel connector comprises a T-shaped connector coupled to thebottom flange on a side thereof opposite the top flange; and furthercomprising sliding the T-shaped connector of each mounting clamp into afastener channel of a respective panel mounting bracket.
 18. The methodof claim 16 wherein the fastener channel connector comprises ahorizontal member having an upper surface coupled to the bottom flangeand a lower surface to be positioned on the distal end of the verticalextension, a pair of spaced apart vertical side members on oppositesides of the horizontal member and configured to extend along the distalend of the vertical extension when the lower surface of the horizontalmember is positioned on the distal end of the vertical extension, a boltcoupled to the lower surface of the horizontal member and configured toextend downward into the fastener channel when the lower surface of thehorizontal member is positioned on the distal end of the verticalextension, and a nut to be screwed onto the bolt; and further comprisingsliding the nut of each mounting clamp into the fastener channel of arespective panel mounting bracket.
 19. The method of claim 16 whereinthe at least one solar panel comprises a plurality of solar panels; andwherein the coupling of the plurality of solar panel mounting assembliesto the at least one solar panel further comprises sliding the fastenerchannel connector of at least two mounting clamps each coupled to theouter frame of different respective solar panels into the fastenerchannel of a same vertical extension.
 20. The method of claim 16 whereinthe coupling of the panel mounting bracket assemblies to the at leastone solar panel further comprises tightening the at least one set screwto secure the lip within the slot.